Dana 300 Help!!!!!!

[biscuit]

I have a Dana 300 transfer case that has twin sticks. I bought the JB conversions heavier spring and ball kit to help with the shifters from jumping out of gear and it came with zero instructions. I went on their website and looked at the product and it has very minimal instructions. The problem that I am having is with the deep bore spring and ball.

These are the steps that I took. I took out the shallow bore rail and removed the stock ball and spring and replaced it with the new heavier spring and stock ball. I put the spring in first then the stock ball. I then installed the shift rail with no problem.

I then removed the deep bore rail and removed the stock spring and ball. Here is where my problem starts. The kit came with two springs and one smaller than stock ball. If you look at the picture below the deep bore shows the smaller ball that came with the kit with the new heavier spring. So I assumed that the small ball goes down in the deep bore then the heavier spring then the stock ball. In theory this will put more pressure on the stock ball that will be riding on the shift rail. I can not push the stock ball down far enough to get the shift rail in. Am I doing some thing wrong? If I put just the spring in without the smaller ball that came with the kit I have no doubt that the rail will go in but this would defeat the purpose of the smaller ball that came with the kit. It almost feels like I have the spring compressed all the way and I still have a good bit of ball in the way of the shift rail.

Any help you can give me will be much appreciated. If you want more information please let me know and I will do my best in getting that for you.

 

[biscuit]

Any help????

 

[bjeep]

It will have to be tight as hell. Or you did not do anything.
Push it with something from the top threw the hole and see
if the ball is below the hole. It will be tight.

 

[biscuit]

It is going to be more that tight.

I did today push the ball and spring down with the shift rail out and there is about 1/16th of a inch (not very accurate) showing not allowing the shift rail to slide in. I was pushing with all 220 lbs of myself and no luck. I have no idea what it could be.

 

[bjeep]

Is they something else in the bottom of the bore?
You may have to drill it a touch deeper. Make sure there is nothing else in there.
Call JB Monday and speak with them.

 

[biscuit]

I have checked the bottom of the bore and it is empty. I will call them Monday as well. Thanks for the help.

 

[bee513]

so you have two detent balls in the deep side? if one is not enought and two is too much go to hardware take spring and find some machine washers close to same size and shim the spring thats what i did on mine

 

[throttlejunkie]

When I did mine it was a pain. I was thinking one spring was different from the other. And also used some washers. But the pos still pops out of gear.

 

[biscuit]

bee513 that is what I will probably end up doing. Throttlejunkie I hate that but I hope mine does not keep doing it. If so I guess I will just live with it. Again thanks for the advise.

 

[biscuit]

Well between traveling for work and my busy life I got the transfer case back in last night and did a little test and everything stayed in gear. I ended up stacking a couple of washers where the ball would go and we will see if that fixed the problem. It will get a good test next weekend at Harlan.

Just for the record don't bother calling JB conversions. They will not call you back or even answer the phone. I called three weeks ago on a Monday July 20th after posting this problem I was having with the spring and ball not fitting. I left a message on the answering machine and have still not heard from them. I called at least 4-5 times each day after that until Friday the 24th. They never answered the phone or called me back. I am work in customer service and deal with people on a daily basis. That is not a way to run a business or have satisfied customers.

Just wanted to say thanks again for the help Hardline.